keep on modifying my TDI

my name is Maurice I live in Holland.
and one of my big passions is tuning my AFN.
years ago I started with building my current engine for my VW vento (jetta III)




setup:
-dbilas 260 camshaft.
-34,5 mm exhaust valve's.
-R520.
-self made Lehmann manifold.
-GT2056V (320 CDI) on a PD manifold.
-ARL head studs.
-AXR rod pistons / lowered compression.
-engine girdle.
-lighter flywheel.
-12mm plunger.
-DE143 camplate.
-snow performance WMI.
-VVT software.







this is with out the WMI.

but to be honest.....the engine never had the response I wanted.
the spool the power band...just something else a bigger turbo but not to much turbo lag.

and when I read JFettig's compound topic I know what I wanted.
and started collecting.

in the beginning I did not know how to match a HPT and a LPT.
so I took R2S kit from a Iveco F1C engine.



I replaced the Iveco K03 for a K03-073 had almost the same comp / turbine size.
let it rebuild with billet wheel and reinforced axial bearing.

there was no way I could get it to fit behind the engine so.



welded MB actros flange on it so I could use a V-band connection.



LPT
compressor size:49/71
turbine size: 55/64 12 blades.
looks a lot like a S250 but I think it's not.

so I started with a complete front of a MK3 to make it all fit.



2 water 2 air 600CFM charge coolers.
then started welding in the available space.







now someone is welding it together.
then I need to make brackets and heat wrap it.

it's far from finished.
and it will take a long time to complete.

first I build it with a 38mm bypass but changed to 60mm when I decided to make it sequential.
but still build as a compound in case sequential would not work.
of course I also have a Audi intake site valve from a 3.0 TDI.

the idea is to make separate cooling systems for the w2a's.
and use PWM to steer the water pump's independent from each other using IAT.
a friend is helping me.
he is the one how build it, sure appreciate that.



this is it so far.
I know there is al lot of experience here with compound and I have non.
so love to here what you think of it so far.

Hi maus nice to show you're build here

Nice setup so far.
For the intercooler pump, I just run mine with key-on power all the time. Wire it off the same relay as your fuel lift pump. Why make it complicated?

Nice build, very cool.

Nice build maurice great setup

Sweet!

Excellent work!

Subscribed for updates!

Amazing!!!

More money than sense.

thank you al.

narongc73 said:

More money than sense.

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It may seem like it but I promise you that's certainly not the case.
first engine cost me 6 years to get ready.
A lot of people with the same VW hobby here try to help each other.
and I'm lucky that I know some knowledgeable people.

I'll realise this project because I'm so interested in VE tuning......not because I've lots to spend.

narongc73 said:

More money than sense.

Click to expand...

To some but not to others. Guess you are the throw away mentality!

I just rebuilt the engine in my wife's wagon and upgraded it, guess that was a waste too, huh?

While there are certainly many prime examples elsewhere, Mister "more money than sense" does not speak for the rest of us. Very keen detailing, I will be most interested and wish you all success in controlling the sequential operation. One question: from what engine actually is the AXR whose pistons and rods you are using?

AXR 101 hp pd with the small big end 50.6 to fit a ve crank they are oil channel in piston crown

Thank you, good to know! Trapezoidal small end?

yes, but there will be a other piston update soon.

Your hardware looks just like mine. Im definitely following this.

long time sins my last post.
i'm still working on the project.
but in a different way, the car had a clean front.
so there was not mutes air coming in there.
I wanted to relocate the fuel cooler from under the car to the front.
there was no opening available for a oil cooler.
had some rust from the rear fender from the wheel hitting the fender.
so I wanted a other / more open front and replace some body panels at the rear and under the car.
but electric orange is not a simple color if you want to spray parts of the body.
so the car is back from a complete paintjob and is carbon black now.
got 4 airducts in the front.
a 3 row grill and E92 bonnet vents all for the compound setup.
the engine is not finished.
but I prepare it for the compound as good as I can.
"3 stainless steel exhaust with simons tublex mid muffler.
so a 50 and 80 PSI dual boost gauge.
a 8ltr buffer tank in the trunk for the 2 W2A coolers.
HPT RPM gauge.
battery en wiper fluid tank to the trunk to make place for the 1st W2A cooler
en a lot of other different wires.

as soon as the car is ready for it and I can drive it again.
I 'll go further with the engine I build in my garage.

narongc73 said:

More money than sense.

Click to expand...

I supose he gave his wife an actual diamond wedding band instead of this:https://www.palmbeachjewelry.com/pr...Anniversary-Ring-in-14k-Gold-Plated-17856.cfm
Seriously, some people should not be allowed to manage their own hard eared money.

So, is it 4 Motion (4 wheel drive) yet? Really great build.

I love this kind of porn! Very nice build, and very impressive engineering!

tnx.

https://www.youtube.com/watch?v=onMwv5IG0CU

finish the car some months ago.
front has al the possible air vents.
and radiator placed backwards in aluminium box to make place for pre radiator.


copper piping for charge cooler system.


buffer tank, and control box.


sand blasted a block en got it ready for oversized BJM crafter pistons.



modified the piston entry and exit for oil

thanks to Bernard I got my drive shaft of the oil pump reinforced.
the axial bearing is replaced for a metal with a lot of chrome in it.
hopefully it will not brake again.
because it has a bad influence on oil pressure. (as on my current engine)



custom drive shaft pulley, 23% smaller used in combination with AAZ timing belt.
there will also be a piston jet upgrade.
so I hope that with the 2 turbo's, bigger jets and 5w-30 oil the pressure will be a lot better than it is now.




LPT has got rebuild it to.
also turbine is "clipt 7 degrees" in the hope for les EMP.
but I fear A/R is way to small even so.



now after 2 months off doing no work on the car what so ever.
I'm back building on the engine a bit in my garage.
connecting the feed pipe on to the HPT.




of course it going to be fully heat wrapt en the I.C pipe thermally protected.